CA3120260C - Additive manufacturing of complex objects using refractory matrix materials - Google Patents
Additive manufacturing of complex objects using refractory matrix materials Download PDFInfo
- Publication number
- CA3120260C CA3120260C CA3120260A CA3120260A CA3120260C CA 3120260 C CA3120260 C CA 3120260C CA 3120260 A CA3120260 A CA 3120260A CA 3120260 A CA3120260 A CA 3120260A CA 3120260 C CA3120260 C CA 3120260C
- Authority
- CA
- Canada
- Prior art keywords
- fuel
- cvi
- envelope
- refractory
- nuclear fuel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 28
- 239000011159 matrix material Substances 0.000 title abstract description 34
- 239000000654 additive Substances 0.000 title abstract description 11
- 230000000996 additive effect Effects 0.000 title abstract description 11
- 238000000034 method Methods 0.000 claims abstract description 48
- 239000000843 powder Substances 0.000 claims abstract description 36
- 239000011230 binding agent Substances 0.000 claims abstract description 16
- 238000007639 printing Methods 0.000 claims abstract description 10
- 238000001764 infiltration Methods 0.000 claims abstract description 5
- 230000008595 infiltration Effects 0.000 claims abstract description 5
- 239000000126 substance Substances 0.000 claims abstract description 5
- 239000003758 nuclear fuel Substances 0.000 claims description 48
- 239000000446 fuel Substances 0.000 claims description 42
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 30
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 30
- 239000002245 particle Substances 0.000 claims description 27
- 238000001816 cooling Methods 0.000 claims description 17
- 239000002243 precursor Substances 0.000 claims description 16
- 238000000151 deposition Methods 0.000 claims description 8
- 239000005055 methyl trichlorosilane Substances 0.000 claims description 7
- JLUFWMXJHAVVNN-UHFFFAOYSA-N methyltrichlorosilane Chemical compound C[Si](Cl)(Cl)Cl JLUFWMXJHAVVNN-UHFFFAOYSA-N 0.000 claims description 7
- 238000011049 filling Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000006096 absorbing agent Substances 0.000 claims description 2
- 239000004215 Carbon black (E152) Substances 0.000 claims 1
- 230000003028 elevating effect Effects 0.000 claims 1
- 229930195733 hydrocarbon Natural products 0.000 claims 1
- 150000002430 hydrocarbons Chemical class 0.000 claims 1
- 229910052710 silicon Inorganic materials 0.000 claims 1
- 239000010703 silicon Substances 0.000 claims 1
- 230000008569 process Effects 0.000 abstract description 15
- 239000011214 refractory ceramic Substances 0.000 abstract description 6
- 239000003870 refractory metal Substances 0.000 abstract description 6
- 239000011248 coating agent Substances 0.000 abstract description 5
- 238000000576 coating method Methods 0.000 abstract description 5
- 238000000280 densification Methods 0.000 abstract description 5
- 239000007789 gas Substances 0.000 description 8
- 238000012856 packing Methods 0.000 description 8
- 239000011819 refractory material Substances 0.000 description 8
- 238000010276 construction Methods 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 229910052770 Uranium Inorganic materials 0.000 description 5
- 229910026551 ZrC Inorganic materials 0.000 description 5
- OTCHGXYCWNXDOA-UHFFFAOYSA-N [C].[Zr] Chemical compound [C].[Zr] OTCHGXYCWNXDOA-UHFFFAOYSA-N 0.000 description 5
- 239000011148 porous material Substances 0.000 description 5
- 230000008021 deposition Effects 0.000 description 4
- 239000012530 fluid Substances 0.000 description 4
- 238000005245 sintering Methods 0.000 description 4
- NXHILIPIEUBEPD-UHFFFAOYSA-H tungsten hexafluoride Chemical compound F[W](F)(F)(F)(F)F NXHILIPIEUBEPD-UHFFFAOYSA-H 0.000 description 4
- JFALSRSLKYAFGM-UHFFFAOYSA-N uranium(0) Chemical compound [U] JFALSRSLKYAFGM-UHFFFAOYSA-N 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 239000000112 cooling gas Substances 0.000 description 3
- 238000010494 dissociation reaction Methods 0.000 description 3
- 230000005593 dissociations Effects 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 229910052750 molybdenum Inorganic materials 0.000 description 3
- 229910052721 tungsten Inorganic materials 0.000 description 3
- WSWMGHRLUYADNA-UHFFFAOYSA-N 7-nitro-1,2,3,4-tetrahydroquinoline Chemical compound C1CCNC2=CC([N+](=O)[O-])=CC=C21 WSWMGHRLUYADNA-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 238000000429 assembly Methods 0.000 description 2
- 230000000712 assembly Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 230000004992 fission Effects 0.000 description 2
- 229910002804 graphite Inorganic materials 0.000 description 2
- 239000010439 graphite Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- GICWIDZXWJGTCI-UHFFFAOYSA-I molybdenum pentachloride Chemical compound Cl[Mo](Cl)(Cl)(Cl)Cl GICWIDZXWJGTCI-UHFFFAOYSA-I 0.000 description 2
- DUNKXUFBGCUVQW-UHFFFAOYSA-J zirconium tetrachloride Chemical compound Cl[Zr](Cl)(Cl)Cl DUNKXUFBGCUVQW-UHFFFAOYSA-J 0.000 description 2
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 239000012159 carrier gas Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005094 computer simulation Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000000635 electron micrograph Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000002803 fossil fuel Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
- C04B35/573—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide obtained by reaction sintering or recrystallisation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/10—Formation of a green body
- B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/1003—Use of special medium during sintering, e.g. sintering aid
- B22F3/1007—Atmosphere
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/1017—Multiple heating or additional steps
- B22F3/1021—Removal of binder or filler
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
- B28B7/46—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for humidifying or dehumidifying
- B28B7/465—Applying setting liquid to dry mixtures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/5607—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on refractory metal carbides
- C04B35/5622—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on refractory metal carbides based on zirconium or hafnium carbides
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/045—Alloys based on refractory metals
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/04—Coating on selected surface areas, e.g. using masks
- C23C16/045—Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/32—Carbides
- C23C16/325—Silicon carbide
-
- G—PHYSICS
- G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
- G21C—NUCLEAR REACTORS
- G21C21/00—Apparatus or processes specially adapted to the manufacture of reactors or parts thereof
- G21C21/02—Manufacture of fuel elements or breeder elements contained in non-active casings
-
- G—PHYSICS
- G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
- G21C—NUCLEAR REACTORS
- G21C21/00—Apparatus or processes specially adapted to the manufacture of reactors or parts thereof
- G21C21/02—Manufacture of fuel elements or breeder elements contained in non-active casings
- G21C21/04—Manufacture of fuel elements or breeder elements contained in non-active casings by vibrational compaction or tamping of fuel in the jacket
-
- G—PHYSICS
- G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
- G21C—NUCLEAR REACTORS
- G21C3/00—Reactor fuel elements and their assemblies; Selection of substances for use as reactor fuel elements
- G21C3/02—Fuel elements
- G21C3/04—Constructional details
- G21C3/042—Fuel elements comprising casings with a mass of granular fuel with coolant passages through them
-
- G—PHYSICS
- G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
- G21C—NUCLEAR REACTORS
- G21C3/00—Reactor fuel elements and their assemblies; Selection of substances for use as reactor fuel elements
- G21C3/02—Fuel elements
- G21C3/28—Fuel elements with fissile or breeder material in solid form within a non-active casing
-
- G—PHYSICS
- G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
- G21C—NUCLEAR REACTORS
- G21C3/00—Reactor fuel elements and their assemblies; Selection of substances for use as reactor fuel elements
- G21C3/30—Assemblies of a number of fuel elements in the form of a rigid unit
- G21C3/32—Bundles of parallel pin-, rod-, or tube-shaped fuel elements
- G21C3/324—Coats or envelopes for the bundles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/241—Chemical after-treatment on the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/248—Thermal after-treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2201/00—Treatment under specific atmosphere
- B22F2201/40—Metal compounds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/20—Refractory metals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
- B22F2302/10—Carbide
- B22F2302/105—Silicium carbide (SiC)
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
- C04B2235/383—Alpha silicon carbide
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3839—Refractory metal carbides
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/40—Metallic constituents or additives not added as binding phase
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
- C04B2235/422—Carbon
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5463—Particle size distributions
- C04B2235/5481—Monomodal
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/602—Making the green bodies or pre-forms by moulding
- C04B2235/6026—Computer aided shaping, e.g. rapid prototyping
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/614—Gas infiltration of green bodies or pre-forms
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/74—Physical characteristics
- C04B2235/77—Density
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/94—Products characterised by their shape
- C04B2235/945—Products containing grooves, cuts, recesses or protusions
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/284—Selection of ceramic materials
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/20—Oxide or non-oxide ceramics
- F05D2300/22—Non-oxide ceramics
- F05D2300/226—Carbides
- F05D2300/2261—Carbides of silicon
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/603—Composites; e.g. fibre-reinforced
- F05D2300/6032—Metal matrix composites [MMC]
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/603—Composites; e.g. fibre-reinforced
- F05D2300/6033—Ceramic matrix composites [CMC]
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0054—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for nuclear applications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E30/00—Energy generation of nuclear origin
- Y02E30/30—Nuclear fission reactors
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- Plasma & Fusion (AREA)
- High Energy & Nuclear Physics (AREA)
- General Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Metallurgy (AREA)
- General Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Composite Materials (AREA)
- Ceramic Products (AREA)
- Chemical Vapour Deposition (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
A method for the manufacture of a three-dimensional object using a refractory matrix material is provided. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic or a refractory metal. In one embodiment, the matrix material is deposited according to a binder-jet printing process to produce a green body having a complex geometry. The CVI process increases its density, provides a hermetic seal, and yields an object with mechanical integrity. The residual binder content dissociates and is removed from the green body prior to the start of the CVI process as temperatures increase in the CVI reactor. The CVI process selective deposits a fully dense coating on all internal and external surfaces of the finished object.
Description
ADDITIVE MANUFACTURING OF COMPLEX OBJECTS
USING REFRACTORY MATRIX MATERIALS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 62/769,588, filed July 31, 2018.
STATEMENT REGARDING FEDERALLY SPONSORED
RESEARCH AND DEVELOPMENT
USING REFRACTORY MATRIX MATERIALS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 62/769,588, filed July 31, 2018.
STATEMENT REGARDING FEDERALLY SPONSORED
RESEARCH AND DEVELOPMENT
[0002] This invention was made with government support under Contract No.
DE-AC05-000R22725 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
FIELD OF THE INVENTION
DE-AC05-000R22725 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention relates to the additive manufacture of complex objects using refractory materials for a variety of energy-related applications.
BACKGROUND OF THE INVENTION
BACKGROUND OF THE INVENTION
[0004] The majority of worldwide energy systems today are designed to convert heat to electricity. The heat may be generated from fossil fuels, solar thermal methods, or nuclear fission or fusion, for example. The second law of thermodynamics dictates that in order to extract the maximum efficiency from heat engines, high operating temperatures are necessary.
A majority of the pathways that allow for conversion of heat to electricity, such as Rankine or Brayton cycles, require a thermal fluid. The ability to achieve high efficiencies requires high fluid temperatures. This in turn requires components that are made from materials that can withstand these high temperatures. These materials may form the combustion vessel or reactor Date Recue/Date Received 2022-06-27 core in a fossil or fission energy system, respectively, as well as piping, heat exchangers, and power conversion components. Refractory materials that can withstand high temperatures are therefore ideal in these applications.
A majority of the pathways that allow for conversion of heat to electricity, such as Rankine or Brayton cycles, require a thermal fluid. The ability to achieve high efficiencies requires high fluid temperatures. This in turn requires components that are made from materials that can withstand these high temperatures. These materials may form the combustion vessel or reactor Date Recue/Date Received 2022-06-27 core in a fossil or fission energy system, respectively, as well as piping, heat exchangers, and power conversion components. Refractory materials that can withstand high temperatures are therefore ideal in these applications.
[0005] While the production of simple geometries (e.g., piping) from refractory metals or ceramics is possible today, components of higher complexity, for example heat exchangers, flanges, and turbines, are not readily produced. The ability to use refractory metals and ceramics for the manufacture of complex components would greatly improve the thermal efficiency of these energy systems, well beyond what is possible with conventional means, for example high temperature Ni-based superalloys. Accordingly, there remains a continued need for methods for the manufacture of components from refractory materials, including for example ceramics and metals, the components having complex three-dimensional geometries for use in energy systems and other applications.
SUMMARY OF THE INVENTION
SUMMARY OF THE INVENTION
[0006] A method for the manufacture of three-dimensional objects using a refractory matrix material is provided. The method generally includes the additive manufacture of a green body from a powder-based refractory matrix material and densification of the green body via chemical gas deposition, for example chemical vapor infiltration (CVI). The refractory matrix material can include a refractory ceramic or a refractory metal, depending on the particular application. The CVI treatment increases the density of the matrix material, provides a hermetic coating, and can form an object with excellent mechanical integrity at extremely high temperatures.
[0007] In one embodiment, the method includes providing a powder feedstock of a suitable refractory matrix material, for example silicon carbide (SiC), zirconium carbide (ZrC), graphite (C), molybdenum (Mo), or tungsten (W). The method includes selectively depositing a binder onto successive layers of the powder feedstock to produce a dimensionally stable Date Recue/Date Received 2022-06-27 green body have the near net-shape of the object being formed, the green body optionally including an undercut, overhang, or internal volume. The green body is heated within a CVI
reactor vessel for debinding, and a precursor gas is introduced for densifying the matrix material. The resulting object includes a substantially pure microstructure with excellent resistance to high temperatures. Example objects include heat exchangers, turbines, flanges, to name only a few.
reactor vessel for debinding, and a precursor gas is introduced for densifying the matrix material. The resulting object includes a substantially pure microstructure with excellent resistance to high temperatures. Example objects include heat exchangers, turbines, flanges, to name only a few.
[0008] In another embodiment, a method for manufacturing an integral nuclear fuel element is provided. The method includes binder-jet printing a fuel envelope using a non-fuel matrix powder. The method further includes filling the envelope with nuclear fuel particles and vibro-packing additional matrix powder to yield a fuel compact therein.
The method further includes performing CVI on the now-filled envelope to seal the nuclear fuel therein.
The resulting nuclear fuel element can include cooling channels integrally formed therein to allow the flow of a cooling fluid, for example helium (He) gas, and can be formed of a material having favorable neutron transparency, for example SiC. The nuclear fuel particles can include an improved packing fraction over existing methods, and the nuclear fuel element can be manufactured at temperatures far below what is necessary for sintering existing fuel matrix materials.
The method further includes performing CVI on the now-filled envelope to seal the nuclear fuel therein.
The resulting nuclear fuel element can include cooling channels integrally formed therein to allow the flow of a cooling fluid, for example helium (He) gas, and can be formed of a material having favorable neutron transparency, for example SiC. The nuclear fuel particles can include an improved packing fraction over existing methods, and the nuclear fuel element can be manufactured at temperatures far below what is necessary for sintering existing fuel matrix materials.
[0009] In another embodiment, the integral nuclear fuel element can include a hexagonal constructional that is stackable as a prismatic block, with a matrix holding the fuel constituents and offering an integral cladding structure. When stacked, the cooling channels of each nuclear fuel element are in fluid communication with the cooling channels of a vertically adjacent nuclear fuel element. The densifled and highly pure refractory envelope can withstand nounal operating temperatures within a reactor core while under neutron irradiation, for example temperatures of between 800 C and 1200 C in a high temperature gas-cooled reactor (H ___________________________________________________ R) reactor. Further, the shape and surface features of the cooling channels can be manufactured with optimized geometries to improve cooling of the nuclear fuel therein, Date Recue/Date Received 2022-06-27 as the thermal energy is optimally transmitted to the cooling gas. Further embodiments include burnable absorbers and/or neutron moderators within the nuclear fuel element.
[0010] As set forth herein, the present method is readily adapted for fabricating objects having complex geometries in applications where high heat resistance is desired. Additive manufacturing of the green body is generally performed at room temperature, and the CVI
furnace operates at temperatures far below sintering temperatures. In embodiments having nuclear fuel contained therein, the packing fraction of nuclear fuel particles was found to be greater than 50%, outpacing the packing density found in pressed and sintered nuclear fuels, resulting in smaller nuclear fuel assemblies.
furnace operates at temperatures far below sintering temperatures. In embodiments having nuclear fuel contained therein, the packing fraction of nuclear fuel particles was found to be greater than 50%, outpacing the packing density found in pressed and sintered nuclear fuels, resulting in smaller nuclear fuel assemblies.
[0011] These and other features of the invention will be more fully understood and appreciated by reference to the description of the embodiments and the drawings.
[0012] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein.
In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including" and "comprising" and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.
Date Recue/Date Received 2022-06-27 BRIEF DESCRIPTION OF THE DRAWINGS
In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including" and "comprising" and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.
Date Recue/Date Received 2022-06-27 BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Figure 1 is a flow chart for manufacturing an object using a refractory material according to one embodiment of the invention.
[0014] Figure 2 is a cross section of a SiC specimen after CVI possessing a dense and hermetic outer layer.
[0015] Figures 3A and 3B are example objects (heat exchanger and turbine blade) manufactured in accordance with one embodiment of the present invention.
[0016] Figure 4 is a process diagram illustrating the additive manufacturing of an integral nuclear fuel element.
[0017] Figure 5 includes top perspective views of integral nuclear fuel element in accordance with additional embodiments.
[0018] Figure 6 includes bottom perspective views of the integral nuclear fuel element of Figure 5.
[0019] Figure 7 is an illustration of a nuclear fuel envelope at different stages of the manufacturing process.
[0020] Figure 8 is an electron micrograph and particle size distribution of a refractory material.
[0021] Figure 9 is a graph showing a representative weight evolution of a green part during heating.
DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS
DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS
[0022] As discussed herein, the current embodiments generally relate to a method for the manufacture of a wide-variety of object using a refractory matrix material. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via CVI. The method of manufacture is generally discussed in Part I below, followed by a description of an integral nuclear fuel element formed according Date Recue/Date Received 2022-06-27 to this method in Part II below. Though described in connection with a nuclear fuel element, the present method is applicable in effectively any application in which a complex three-dimensional object requires high heat resistance, including heat exchangers, flanges, and turbines blades for example. Similarly, just as nuclear fuel may be embedded inside the refractory matrix, other constitutes and devices may be incorporated into the matrix.
I. Method of Manufacture
I. Method of Manufacture
[0023] A method according to one embodiment includes the manufacture of a three-dimensional object using a refractory matrix material. With reference to Figure 1, the method generally includes (a) the selection of a refractory feedstock, (b) the additive manufacture of a green body using the refractory feedstock, (c) the introduction of a refractory gaseous precursor for CVI, (d) CVI of the green body for densification and removal of the binder, and (e) the completion of the final part having a complex three-dimensional geometry. Each such operation is separately discussed below.
[0024] The selection of a refractory feedstock at step 10 includes the selection of a refractory ceramic powder feedstock or a refractory metal powder feedstock. A
suitable refractory ceramic can include, for example, SiC, C, or ZrC, and a suitable refractory metal can include, for example, Mo or W. At step 12, the green body is formed according to an additive manufacturing process to produce a three-dimensional object. In the current embodiment, the green body is formed according to a binder-jet printing process. In the binder-jet printing process, a powder bed of the refractory material is printed at ambient temperatures with a binder pattern layer-by-layer, as optionally set forth in U.S. Patent 5,204,055 to Sachs et al and U.S. Patent 5,387,380 to Cima et al. More particularly, the powder feedstock is deposited in sequential layers, one on top of the other. Following the deposit of each layer of powder feedstock, a liquid binder material, for example a polymeric binder, is selectively supplied to the layer of powder feedstock in accordance with a computer model (e.g., CAD
model) of the three-dimensional object being formed.
Date Recue/Date Received 2022-06-27
suitable refractory ceramic can include, for example, SiC, C, or ZrC, and a suitable refractory metal can include, for example, Mo or W. At step 12, the green body is formed according to an additive manufacturing process to produce a three-dimensional object. In the current embodiment, the green body is formed according to a binder-jet printing process. In the binder-jet printing process, a powder bed of the refractory material is printed at ambient temperatures with a binder pattern layer-by-layer, as optionally set forth in U.S. Patent 5,204,055 to Sachs et al and U.S. Patent 5,387,380 to Cima et al. More particularly, the powder feedstock is deposited in sequential layers, one on top of the other. Following the deposit of each layer of powder feedstock, a liquid binder material, for example a polymeric binder, is selectively supplied to the layer of powder feedstock in accordance with a computer model (e.g., CAD
model) of the three-dimensional object being formed.
Date Recue/Date Received 2022-06-27
[0025] Once the three-dimensional object is completed, the unbound powder is removed, yielding a near net-shaped green body held together by the removable polymeric binder. The green body can have a binder content on the order of a few wt%, for example 1-5%, with a density of about 30-55% of their theoretical limit. For example, the green body is a dimensionally stable object of greater than 30% by weight of SiC (or other refractory material) in one embodiment, further optionally greater than 50% by weight SiC
(or other refractory material) in other embodiments. At step 14, a gaseous refractory precursor for CVI
is selected, such that the finished object can include a highly pure and uniform matrix. For example, the gaseous refractory precursor for CVI of a SiC green body can include MethylTrichloroSilane (MTS) that gives SiC by the MTS decomposing. Further by example, the gaseous refractory precursor for a ZrC green body can include zirconium tetrachloride (ZrC14) gas, the gaseous refractory precursor for a graphite (C) green body can include methane (CI-14) gas, the gaseous refractory precursor for CVI of a W green body can include tungsten hexafluoride (WF6) gas, and the gaseous refractory precursor for CVI of a Mo green body can include molybdenum hexafluoride (MoF6) or molybdenum pentachloride (MoC15) gas. In other embodiments, however, a composite matrix may be realized by printing one material in powder form and depositing another material around the powder with CVI.
(or other refractory material) in other embodiments. At step 14, a gaseous refractory precursor for CVI
is selected, such that the finished object can include a highly pure and uniform matrix. For example, the gaseous refractory precursor for CVI of a SiC green body can include MethylTrichloroSilane (MTS) that gives SiC by the MTS decomposing. Further by example, the gaseous refractory precursor for a ZrC green body can include zirconium tetrachloride (ZrC14) gas, the gaseous refractory precursor for a graphite (C) green body can include methane (CI-14) gas, the gaseous refractory precursor for CVI of a W green body can include tungsten hexafluoride (WF6) gas, and the gaseous refractory precursor for CVI of a Mo green body can include molybdenum hexafluoride (MoF6) or molybdenum pentachloride (MoC15) gas. In other embodiments, however, a composite matrix may be realized by printing one material in powder form and depositing another material around the powder with CVI.
[0026] At step 16, the green body is placed in a CVI furnace (reactor vessel) into which the gaseous precursor and carrier gas that could be inert (e.g. Ar) or otherwise (e.g. H2) is admitted. The pressure and temperature within the furnace and the composition, partial pressure and flow rate of the gaseous precursor are selected to allow the gaseous precursor to diffuse within the pores of the green body. More specifically, CVI involves the temperature decomposition of the gaseous precursor (e.g., MTS or WF6) and the infiltration and then absorption of the decomposed precursor within the pores of the matrix material (e.g., SiC or W). The CVI process for SiC involves a process temperature of between 850 C
and 1300 C, 1000 C and 1200 C, optionally 1100 C, which is far below the temperatures required for Date Recue/Date Received 2022-06-27 sintering in existing methods (-2000 C). Of note, as the temperatures increase within the CVI
furnace, the binder dissociates and is removed prior to the start of the CVI
process. The CVI
process initially uniformly densifies the green body, and as the pores inside the green body become closed, the CVI selectively deposits a fully dense coating on all internal and external surfaces of the three-dimensional object. The densified green body can include a density of greater than 85% by weight of SiC in some embodiments, and greater than 90% by weight of SiC in other embodiments. This phenomenon is further illustrated in Figure 2, which includes a cross-section of a binder-jet printed SiC specimen having a complex geometry. The cross-section includes a dense and hermetic outer layer with a thickness on the order of 20 to 200 Jim, further optionally 50 to 100 gm. As also shown in the inset of Figure 2, a continuous CVI
SiC matrix is deposited around the SiC powders, such that the microstructure includes both the original 3D printed SiC powder and a continuous CVI SiC matrix.
and 1300 C, 1000 C and 1200 C, optionally 1100 C, which is far below the temperatures required for Date Recue/Date Received 2022-06-27 sintering in existing methods (-2000 C). Of note, as the temperatures increase within the CVI
furnace, the binder dissociates and is removed prior to the start of the CVI
process. The CVI
process initially uniformly densifies the green body, and as the pores inside the green body become closed, the CVI selectively deposits a fully dense coating on all internal and external surfaces of the three-dimensional object. The densified green body can include a density of greater than 85% by weight of SiC in some embodiments, and greater than 90% by weight of SiC in other embodiments. This phenomenon is further illustrated in Figure 2, which includes a cross-section of a binder-jet printed SiC specimen having a complex geometry. The cross-section includes a dense and hermetic outer layer with a thickness on the order of 20 to 200 Jim, further optionally 50 to 100 gm. As also shown in the inset of Figure 2, a continuous CVI
SiC matrix is deposited around the SiC powders, such that the microstructure includes both the original 3D printed SiC powder and a continuous CVI SiC matrix.
[0027] Completion of the final part is depicted at step 18. Owing to the formation of the green body by additive manufacturing, the finished article can possess almost any geometry, including overhangs, undercuts, and internal volumes. As shown in Figure 3A for example, green body can include a heat exchanger 20 having a multi-channel primary loop 22 and a helical secondary loop 24 (or vice versa), each defining a complex internal volume not readily formed according to conventional methods. As alternatively shown in Figure 3B for example, the present method can be used to form a turbine blade 26 or other objects whose manufacture is difficult or not possible according to conventional methods.
Integral Nuclear Fuel Element
Integral Nuclear Fuel Element
[0028] An integral nuclear fuel element and its method of manufacture will now be described. As set forth below, the integral nuclear fuel element generally includes a CVI-densified fuel envelope formed of a 3D printed refractory matrix material and containing uniformly dispersed fuel particles therein, for example 1RISO nuclear fuel particles, the fuel envelope optionally being shaped as a prismatic fuel block.
Date Recue/Date Received 2022-06-27
Date Recue/Date Received 2022-06-27
[0029] As shown in Figures 4-7, an integral nuclear fuel element is formed by binder-jet printing a rigid envelope 30 from a refractory powder feedstock. The envelope 30 can include any construction having at least one internal volume (or cavity) 32 for a nuclear fuel and optionally at least one cooling channel 34. In the illustrated embodiments, the internal volume 34 is defined between an outer sidewall 36, an inner sidewall 38, a base 40, and a cap 42, the internal volume 32 being accessible through one or more openings 44 in the cap 42.
The envelope 30 includes a hexagonal construction in the present embodiment, but can include other constructions in other embodiments, including for example cylindrical or any other construction including those that are axial and radially asymmetric. In the embodiment shown in Figure 4, a single cooling channel 34 extends vertically through the center of the envelope
The envelope 30 includes a hexagonal construction in the present embodiment, but can include other constructions in other embodiments, including for example cylindrical or any other construction including those that are axial and radially asymmetric. In the embodiment shown in Figure 4, a single cooling channel 34 extends vertically through the center of the envelope
30, interconnecting the base 40 with the cap 42, such that the internal volume 32 concentrically surrounds the cooling channel 34. In the embodiments of Figures 5 and 6, multiple cooling channels 34 extend vertically through the envelope 30, but differ from the cooling channel of Figure 4 in that the cooling channels of Figures 5 and 6 are non-linear or curvilinear, diverging and/or converging, and optionally port the cooling gas from the envelope at a non-zero angle relative to vertical. Because the binder-jet printing process can accommodate overhangs, undercuts, and internal volumes, the internal volume and the cooling channel can achieve effectively any geometry, with the geometries of Figures 4-6 being depicted for illustrative purposes. Figure 7 shows the general manufacturing steps for the nuclear fuel envelope of Figures 5 and 6 with the leftmost illustration showing the CAD model for the fuel envelope, the center illustration showing the 3D printed envelope and the rightmost illustration showing the CVI-densified fuel envelope (without the fuel particles for the sake of disclosure).
[0030] The envelope is generally formed of a non-fuel refractory powder feedstock.
Examples include SiC, C, ZrC, Mo, and W. Figure 8 shows an SiC powder morphology and size distribution suitable for use in manufacturing the fuel envelope.
Refractory powders in a range of alternative morphologies and alternative size distributions may be used in alternative Date Recue/Date Received 2022-06-27 applications. In this embodiment, the SiC powder is a-SiC (hexagonal phase) feedstock from Sigma Aldrich with a purity >99.5%. The powder feedstock is deposited in successive layers according to a binder-jet printing process, with a liquid binder being selectively supplied to each layer of powder feedstock in accordance with the CAD model of the envelope. In the illustrated embodiment, the envelope is 3D printed using an Innovent binderjet system from ExOne Company (North Huntingdon, PA). The envelope may, however, be formed using a wide variety of alternative binder-jet printers. After printing, the powder bed may undergo a binder curing step that drives off the majority of the aqueous or organic-based solvent. For example, the powder bed may be heated at about 190 C for approximately 6 hours in air.
[0030] The envelope is generally formed of a non-fuel refractory powder feedstock.
Examples include SiC, C, ZrC, Mo, and W. Figure 8 shows an SiC powder morphology and size distribution suitable for use in manufacturing the fuel envelope.
Refractory powders in a range of alternative morphologies and alternative size distributions may be used in alternative Date Recue/Date Received 2022-06-27 applications. In this embodiment, the SiC powder is a-SiC (hexagonal phase) feedstock from Sigma Aldrich with a purity >99.5%. The powder feedstock is deposited in successive layers according to a binder-jet printing process, with a liquid binder being selectively supplied to each layer of powder feedstock in accordance with the CAD model of the envelope. In the illustrated embodiment, the envelope is 3D printed using an Innovent binderjet system from ExOne Company (North Huntingdon, PA). The envelope may, however, be formed using a wide variety of alternative binder-jet printers. After printing, the powder bed may undergo a binder curing step that drives off the majority of the aqueous or organic-based solvent. For example, the powder bed may be heated at about 190 C for approximately 6 hours in air.
[0031] Once the envelope is fully printed, the unbound powder is removed, yielding for example the near net-shaped green body shown at left in Figure 4.
Subsequent to the formation of the green body, and prior to CVI, fuel particles 46 are added to the internal fuel cavity. The fuel particles can include uranium or other fissile elements, and can be bare fuel kernels or coated particles, for example tri-structural isotropic (TRISO) particles, bi-structural isotropic (BISO) particles, and bare uranium-bearing (e.g., UO2, UC, UN, or there combinations) spheres (fuel kernels) containing fissile uranium. Further optionally, the fuel particles can include a combination of bare fuel kernels and coated particles.
The fuel particles are added to the internal cavity according to any desired technique, for example from a hopper, until substantially full. Additional matrix powder feedstock is then added to the internal cavity, being at least an order of magnitude smaller than the fuel particles, to occupy the voids between adjacent fuel particles, while also coating the exposed fuel particles at the openings 44. Further optionally, the additional matrix powder feedstock can be vibro-packed to ensure maximum densification prior to chemical vapor infiltration.
Subsequent to the formation of the green body, and prior to CVI, fuel particles 46 are added to the internal fuel cavity. The fuel particles can include uranium or other fissile elements, and can be bare fuel kernels or coated particles, for example tri-structural isotropic (TRISO) particles, bi-structural isotropic (BISO) particles, and bare uranium-bearing (e.g., UO2, UC, UN, or there combinations) spheres (fuel kernels) containing fissile uranium. Further optionally, the fuel particles can include a combination of bare fuel kernels and coated particles.
The fuel particles are added to the internal cavity according to any desired technique, for example from a hopper, until substantially full. Additional matrix powder feedstock is then added to the internal cavity, being at least an order of magnitude smaller than the fuel particles, to occupy the voids between adjacent fuel particles, while also coating the exposed fuel particles at the openings 44. Further optionally, the additional matrix powder feedstock can be vibro-packed to ensure maximum densification prior to chemical vapor infiltration.
[0032] Subsequent to filling and vibro-packing the envelope with fuel particles and optional additional matrix material, the envelope is inserted within a CVI
furnace and elevated to a temperature that is ideal for the specific CVI process. For instances, a temperature of Date Recue/Date Received 2022-06-27 between 850 C and 1300 C, 1000 C and 1200 C, optionally 1100 C, is ideal for SiC
deposition with MTS, while temperatures < 750 C are ideal for W deposition using WF6. As the temperature is elevated in the CVI furnace, the polymeric binder dissociates starting at ¨200 C with dissociation complete at 500 C. During dissociation, the continuous inert gas flow in the CVI furnace vessel purges binder dissociation products. Once at the target CVI
temperature, a gaseous precursor is introduced within the CVI furnace to allow additional matrix material deposition within the pores of the envelope. As the pores inside the envelope become closed, the CVI process selectively deposits a fully dense coating on all internal and external surfaces of the envelope. The resulting microstructure of the envelope includes high purity and an optionally uniform matrix, while sealing the nuclear fuel particles therein. As shown at right in Figure 4, a cross-section of the resulting integral nuclear fuel element include a dense fuel compact with uranium fuel particles embedded in a hermetically sealed refractory envelope. The content of the matrix material in the densified envelope is greater than 85% in some embodiments, further optionally 90% in other embodiments, and still further optionally greater than 95% in other embodiments. Further, the matrix material (e.g., SiC) can comprise less than the 25% by volume of the integral nuclear fuel element. Figure 9 shows the weight evolution in a green part produced with an aqueous binder after the optional curing step and upon heating in Ar to high temperature.
furnace and elevated to a temperature that is ideal for the specific CVI process. For instances, a temperature of Date Recue/Date Received 2022-06-27 between 850 C and 1300 C, 1000 C and 1200 C, optionally 1100 C, is ideal for SiC
deposition with MTS, while temperatures < 750 C are ideal for W deposition using WF6. As the temperature is elevated in the CVI furnace, the polymeric binder dissociates starting at ¨200 C with dissociation complete at 500 C. During dissociation, the continuous inert gas flow in the CVI furnace vessel purges binder dissociation products. Once at the target CVI
temperature, a gaseous precursor is introduced within the CVI furnace to allow additional matrix material deposition within the pores of the envelope. As the pores inside the envelope become closed, the CVI process selectively deposits a fully dense coating on all internal and external surfaces of the envelope. The resulting microstructure of the envelope includes high purity and an optionally uniform matrix, while sealing the nuclear fuel particles therein. As shown at right in Figure 4, a cross-section of the resulting integral nuclear fuel element include a dense fuel compact with uranium fuel particles embedded in a hermetically sealed refractory envelope. The content of the matrix material in the densified envelope is greater than 85% in some embodiments, further optionally 90% in other embodiments, and still further optionally greater than 95% in other embodiments. Further, the matrix material (e.g., SiC) can comprise less than the 25% by volume of the integral nuclear fuel element. Figure 9 shows the weight evolution in a green part produced with an aqueous binder after the optional curing step and upon heating in Ar to high temperature.
[0033] The integral nuclear fuel element includes a generally stackable construction.
When arranged and stacked, the cooling channel(s) of each nuclear fuel element are in fluid communication with the cooling channel(s) of a vertically adjacent nuclear fuel element. The densified and highly pure refractory envelope can withstand normal operating temperatures within a reactor core, for example the reactor core of a high temperature gas-cooled reactor (HTGR) having a Brayton closed-cycle gas turbine or other power conversion means. In addition, the nuclear fuel within the nuclear fuel element includes an increased packing fraction over conventional fuels. For example, existing methods (pressing and sintering) provide Date Recue/Date Received 2022-06-27 packing fractions of up to 45%. By contrast, the packing fraction of the nuclear fuel particles within the fuel envelope of the present invention can be greater than 50%. As a result, nuclear fuel assemblies including the integral nuclear fuel elements of present invention can be made more compact. Further, the cooling channels can be manufactured with optimized geometries and surface features to improve cooling of the nuclear fuel compact therein, as the thermal energy is optimally transmitted to the cooling gas.
When arranged and stacked, the cooling channel(s) of each nuclear fuel element are in fluid communication with the cooling channel(s) of a vertically adjacent nuclear fuel element. The densified and highly pure refractory envelope can withstand normal operating temperatures within a reactor core, for example the reactor core of a high temperature gas-cooled reactor (HTGR) having a Brayton closed-cycle gas turbine or other power conversion means. In addition, the nuclear fuel within the nuclear fuel element includes an increased packing fraction over conventional fuels. For example, existing methods (pressing and sintering) provide Date Recue/Date Received 2022-06-27 packing fractions of up to 45%. By contrast, the packing fraction of the nuclear fuel particles within the fuel envelope of the present invention can be greater than 50%. As a result, nuclear fuel assemblies including the integral nuclear fuel elements of present invention can be made more compact. Further, the cooling channels can be manufactured with optimized geometries and surface features to improve cooling of the nuclear fuel compact therein, as the thermal energy is optimally transmitted to the cooling gas.
[0034] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles "a," "an," "the" or "said," is not to be construed as limiting the element to the singular.
Date Recue/Date Received 2022-06-27
Date Recue/Date Received 2022-06-27
Claims (5)
1. A method for manufacturing an integral nuclear fuel element, the method comprising:
providing a first powder feedstock of silicon carbide;
binder-jet printing a fuel envelope by selectively depositing a binder onto successive layers of the first powder feedstock, the fuel envelope being rigid and of greater than 30% by weight of silicon carbide, wherein the fuel envelope has an outer sidewall, one or more inner sidewalls, a base and a cap that define therebetween an internal fuel cavity, the internal fuel cavity being accessible through one or more openings in the cap, and wherein the one or more inner sidewalls surround a cooling channel that interconnects the base with the cap;
filling the internal fuel cavity by introducing nuclear fuel particles through the one or more openings and subsequently introducing a second powder feedstock of silicon carbide through the one or more openings, the second powder feedstock of silicon carbide being interposed between the nuclear fuel particles within the internal fuel cavity;
positioning the fuel envelope having its internal fuel cavity filled with the nuclear fuel particles and the second feedstock of silicon carbide within a chemical vapor infiltration (CVI) reactor and introducing within the CVI reactor a precursor gas including silicon and a hydrocarbon to densify the fuel envelope to a content of silicon carbide of greater than 85% by weight and to hermetically seal the nuclear fuel particles within the internal fuel cavity of the densified fuel envelope to obtain the integral nuclear fuel element with a content of silicon carbide of less than 25% by volume.
providing a first powder feedstock of silicon carbide;
binder-jet printing a fuel envelope by selectively depositing a binder onto successive layers of the first powder feedstock, the fuel envelope being rigid and of greater than 30% by weight of silicon carbide, wherein the fuel envelope has an outer sidewall, one or more inner sidewalls, a base and a cap that define therebetween an internal fuel cavity, the internal fuel cavity being accessible through one or more openings in the cap, and wherein the one or more inner sidewalls surround a cooling channel that interconnects the base with the cap;
filling the internal fuel cavity by introducing nuclear fuel particles through the one or more openings and subsequently introducing a second powder feedstock of silicon carbide through the one or more openings, the second powder feedstock of silicon carbide being interposed between the nuclear fuel particles within the internal fuel cavity;
positioning the fuel envelope having its internal fuel cavity filled with the nuclear fuel particles and the second feedstock of silicon carbide within a chemical vapor infiltration (CVI) reactor and introducing within the CVI reactor a precursor gas including silicon and a hydrocarbon to densify the fuel envelope to a content of silicon carbide of greater than 85% by weight and to hermetically seal the nuclear fuel particles within the internal fuel cavity of the densified fuel envelope to obtain the integral nuclear fuel element with a content of silicon carbide of less than 25% by volume.
2. The method of claim I wherein the precursor gas includes methyltrichlorosilane (MTS).
Date Recue/Date Received 2023-09-25
Date Recue/Date Received 2023-09-25
3. The method of claim 1 wherein depositing a binder onto successive layers of the first powder feedstock is performed at ambient temperature.
4. The method of claim 1 further including elevating the temperature within the CVI reactor by heating the CVI reactor to between 850 C and 1300 C.
5. The method of claim 1 further including introducing, through the one or more openings, a burnable absorber or a neutron moderator along with the nuclear fuel particles and the second powder feedstock of silicon carbide.
Date Recue/Date Received 2023-09-25
Date Recue/Date Received 2023-09-25
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA3213973A CA3213973A1 (en) | 2018-11-20 | 2019-07-31 | Additive manufacturing of complex objects using refractory matrix materials |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201862769588P | 2018-11-20 | 2018-11-20 | |
US62/769,588 | 2018-11-20 | ||
PCT/US2019/044276 WO2020106334A1 (en) | 2018-11-20 | 2019-07-31 | Additive manufacturing of complex objects using refractory matrix materials |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA3213973A Division CA3213973A1 (en) | 2018-11-20 | 2019-07-31 | Additive manufacturing of complex objects using refractory matrix materials |
Publications (2)
Publication Number | Publication Date |
---|---|
CA3120260A1 CA3120260A1 (en) | 2020-05-28 |
CA3120260C true CA3120260C (en) | 2024-01-23 |
Family
ID=70728749
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA3120260A Active CA3120260C (en) | 2018-11-20 | 2019-07-31 | Additive manufacturing of complex objects using refractory matrix materials |
CA3213973A Pending CA3213973A1 (en) | 2018-11-20 | 2019-07-31 | Additive manufacturing of complex objects using refractory matrix materials |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA3213973A Pending CA3213973A1 (en) | 2018-11-20 | 2019-07-31 | Additive manufacturing of complex objects using refractory matrix materials |
Country Status (7)
Country | Link |
---|---|
US (2) | US11285635B2 (en) |
EP (1) | EP3883905A1 (en) |
JP (1) | JP7197696B2 (en) |
KR (1) | KR102567434B1 (en) |
CN (1) | CN113227017B (en) |
CA (2) | CA3120260C (en) |
WO (1) | WO2020106334A1 (en) |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR101677175B1 (en) * | 2015-08-07 | 2016-11-21 | 서울시립대학교 산학협력단 | Composition of fully ceramic microencapsulated fuels containing tristructural-isotropic particles with a coating layer having higher shrinkage than matrix, material and manufacturing method of the same |
WO2020028821A1 (en) * | 2018-08-03 | 2020-02-06 | Lawrence Livermore National Security, Llc | Reactive precursors for unconventional additive manufactured components |
US20200234834A1 (en) * | 2019-01-18 | 2020-07-23 | BWXT Advanced Technologies LLC | Nuclear reactor fuel assemblies and process for production |
US11289212B2 (en) | 2019-09-30 | 2022-03-29 | BWXT Advanced Technologies LLC | Fission reactor with segmented cladding bodies having cladding arms with involute curve shape |
US11935661B2 (en) * | 2020-10-12 | 2024-03-19 | Bwxt Nuclear Energy, Inc. | Cermet fuel element and fabrication and applications thereof, including in thermal propulsion reactor |
CN116462512B (en) * | 2023-05-10 | 2024-06-18 | 中国科学院重庆绿色智能技术研究院 | High-density pure silicon carbide manufactured by additive material, and preparation method and application thereof |
Family Cites Families (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE581473A (en) * | 1958-08-08 | |||
US3166614A (en) * | 1959-11-30 | 1965-01-19 | Carborundum Co | Process of making nuclear fuel element |
US2941933A (en) * | 1959-11-30 | 1960-06-21 | William E Roake | Fuel element for nuclear reactor |
US3413196A (en) * | 1965-09-08 | 1968-11-26 | Atomic Energy Commission Usa | Fuel element |
US5387380A (en) | 1989-12-08 | 1995-02-07 | Massachusetts Institute Of Technology | Three-dimensional printing techniques |
US5204055A (en) | 1989-12-08 | 1993-04-20 | Massachusetts Institute Of Technology | Three-dimensional printing techniques |
EP0835853A1 (en) | 1996-10-14 | 1998-04-15 | Societe Europeenne De Propulsion | Friction element made of carbon/carbon-silicon carbide composite material and method of making it |
DE69804161T2 (en) * | 1997-06-20 | 2002-08-14 | Bridgestone Corp | Component for semiconductor equipment |
FR2807563B1 (en) * | 2000-04-07 | 2002-07-12 | Framatome Sa | NUCLEAR FUEL ASSEMBLY FOR A LIGHT WATER-COOLED REACTOR COMPRISING A NUCLEAR FUEL MATERIAL IN THE FORM OF PARTICLES |
FR2857660B1 (en) * | 2003-07-18 | 2006-03-03 | Snecma Propulsion Solide | THERMOSTRUCTURAL COMPOSITE STRUCTURE HAVING A COMPOSITION GRADIENT AND METHOD OF MANUFACTURING THE SAME |
FR2936088B1 (en) * | 2008-09-18 | 2011-01-07 | Commissariat Energie Atomique | NUCLEAR FUEL TANK WITH HIGH THERMAL CONDUCTIVITY AND METHOD OF MANUFACTURING THE SAME. |
US9975815B2 (en) * | 2015-02-26 | 2018-05-22 | General Electric Company | Methods for forming ceramic matrix composite articles |
CN106278335B (en) | 2016-08-05 | 2019-02-05 | 西安交通大学 | A kind of manufacturing method of fiber alignment toughening ceramic based composites turbo blade |
WO2018136631A2 (en) * | 2017-01-18 | 2018-07-26 | The University Of North Carolina At Charlotte | Composite carbide compositions and methods of making the same |
CN107098714B (en) * | 2017-04-26 | 2020-06-19 | 西安交通大学 | Silicon carbide-based ceramic part manufacturing method based on 3DP additive manufacturing technology |
CN107253861A (en) * | 2017-07-05 | 2017-10-17 | 哈尔滨理工大学 | A kind of method that SLS/CVI prepares high-strength high temperature-resistant SiC ceramic engine blade wheel |
CN108083812A (en) * | 2017-12-19 | 2018-05-29 | 西安交通大学 | A kind of increasing material production method of labyrinth ceramic base part |
CN108706978B (en) * | 2018-06-08 | 2020-11-06 | 西北工业大学 | Method for preparing silicon carbide ceramic matrix composite by combining spray granulation with 3DP and CVI |
-
2019
- 2019-07-31 EP EP19752821.9A patent/EP3883905A1/en active Pending
- 2019-07-31 WO PCT/US2019/044276 patent/WO2020106334A1/en active Application Filing
- 2019-07-31 CA CA3120260A patent/CA3120260C/en active Active
- 2019-07-31 JP JP2021527963A patent/JP7197696B2/en active Active
- 2019-07-31 US US16/527,317 patent/US11285635B2/en active Active
- 2019-07-31 KR KR1020217018344A patent/KR102567434B1/en active IP Right Grant
- 2019-07-31 CA CA3213973A patent/CA3213973A1/en active Pending
- 2019-07-31 CN CN201980076497.6A patent/CN113227017B/en active Active
-
2022
- 2022-03-24 US US17/702,929 patent/US11919815B2/en active Active
Also Published As
Publication number | Publication date |
---|---|
JP2022509125A (en) | 2022-01-20 |
US11285635B2 (en) | 2022-03-29 |
KR20210092781A (en) | 2021-07-26 |
EP3883905A1 (en) | 2021-09-29 |
CN113227017A (en) | 2021-08-06 |
CA3120260A1 (en) | 2020-05-28 |
CA3213973A1 (en) | 2020-05-28 |
JP7197696B2 (en) | 2022-12-27 |
US11919815B2 (en) | 2024-03-05 |
US20220212363A1 (en) | 2022-07-07 |
US20200156282A1 (en) | 2020-05-21 |
WO2020106334A1 (en) | 2020-05-28 |
KR102567434B1 (en) | 2023-08-16 |
CN113227017B (en) | 2023-04-18 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA3120260C (en) | Additive manufacturing of complex objects using refractory matrix materials | |
US9224506B2 (en) | Method of manufacturing nuclear fuel elements and a container for implementing such a method | |
US10109378B2 (en) | Method for fabrication of fully ceramic microencapsulation nuclear fuel | |
US20130077731A1 (en) | Ceramic encapsulations for nuclear materials and systems and methods of production and use | |
CN109074877B (en) | Improved toughness of microencapsulated nuclear fuels | |
WO2008121513A2 (en) | Fuel elements for nuclear reactor system | |
EP3685407B1 (en) | High temperature ceramic nuclear fuel system for light water reactors and lead fast reactors | |
Trammell et al. | Advanced Nuclear Fuel Fabrication: Particle Fuel Concept for TCR | |
JP2024507583A (en) | reactor fuel | |
CN110306074B (en) | Discharge plasma sintering preparation method of CERMET fuel pellet | |
US20230207142A1 (en) | High efficiency foam compacts for triso fuels | |
RU2522744C2 (en) | Composite fuel model material with inert porous metal matrix and method for production thereof | |
US11728045B2 (en) | 3D printing of additive structures for nuclear fuels | |
CN113658724B (en) | Ceramic composite fuel pellet and preparation method and application thereof | |
US20240021332A1 (en) | Overmolded fuel pellets and methods of manufacture thereof | |
Seibert et al. | Progress on Synthesis of Low Content Inert Matrix Fuel Pellets | |
CN117373702A (en) | Multiple-cladding dispersion fuel element with high safety characteristic and complex structure and preparation method thereof |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
EEER | Examination request |
Effective date: 20210517 |
|
EEER | Examination request |
Effective date: 20210517 |
|
EEER | Examination request |
Effective date: 20210517 |
|
EEER | Examination request |
Effective date: 20210517 |
|
EEER | Examination request |
Effective date: 20210517 |
|
EEER | Examination request |
Effective date: 20210517 |
|
EEER | Examination request |
Effective date: 20210517 |
|
EEER | Examination request |
Effective date: 20210517 |
|
EEER | Examination request |
Effective date: 20210517 |